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EMBOSSER-KNIFE UNIT 3 Sheets-Sheet 2 Filed Jan. 5, 1961 INVENTOR.` Cuer- 6. Jon BY v-LJMYM A T7'DENEY5 Dec. 24, 1963 G, OA

EMBOSSER-KNIFE UNIT 3 Sheets-Sheet 3 Filed Jan. 5, 1961 INVENTOR. CM??- 6. ./an BY rM/I-Lf United States Patent O 3,114,994 EMIESSER-KNIFE UNIT Curt G. loa, Ocean Ridge, Fia. (Box 1121, Boynton Beach, Fia.) Filed Jan. 5, 1961, Ser. No. 80,882 4- Claims. (Cl. 53-182) This invention relates to an improved embosser-knife unit of the type shown in my copending application Serial No. 760,963, filed September 15, 1958, now U.S. Patent No. 3,020,687, a Knife Lock arid Control Means Therefor.

In the apparatus shown in the copending application aforesaid, the embosser-knife unit functions under the control of an electrical control circuit for sequentially embossing and cutting through gap areas between discrete batt segments ensleeved between wrapper sheets.

The present invention improves on the device of the prior application in that the knife may be inter-locked against actuation with respect to certain of said gaps so that the cushion or pad product which results from the operation of the machine may consist of an interconnected series of spaced pads connected together on flexible links which may be bent about the corners of objects cushioned thereby, thus to more easily conform the pad to the shape of the object.

A specific use for such pads is in the cushioning of furniture during shipment where it is desired that the pad be disposed against the various finished surfaces of the furniture piece. According to the present invention, segmented pads may be fabricated with blendable links which will permit shaping the pad to the furniture without any requirement to use a separate pad for each furniture face.

The present invention also improves on the structure shown in the said copending application in the mechanism for driving the embosser-knife unit on its path parallel to the conveyor on which the batt strips are conveyed. The copending application shows a mid-point drive. For larger units of the type herein shown, the unit carriage is driven at both its marigns to prevent side sways, etc.

Other objects, features and advantages of the invention will appear from the following disclosure in which:

FIG. l is a fragmentary perspective view illustrating diagrammatically the operation of the combined embosser-knife unit.

FIG. 2 is a fragmentary side elevation of an embosserknife unit embodying the present invention, parts being broken away and shown in cross section.

FIG. 3 is a fragmentary end elevation of the device shown in FIG. 2, portions thereof being broken away and shown in cross section.

FIG. 4 is a cross section taken along the line 444 of FIG. 3.

FIG. 5 is a fragmentary view partially in cross section showing the spaced relation of the embosser-knife unit, its anvil and the envelope for the ensleeved pads prior to the embossing step.

FIG. 6 is a view similar to that shown in FIG. 5, but showing the embosser-knife unit in the course of ernbossing and serving the envelope across the gap between spaced pad segments.

FIG. 7 is a detailed view showing the relationship between the various control -switches and cams which operate them.

FIG. 8 is a simplified schematic electrical circuit diagram showing thepswitches of FIG. 7 in circuit with electrical components controlled therein.

FIGS. 9 through 1l show the specific configuration of various cams used in the structure shown in FIG. 7.

FIGS. 12 through 14 show diagrammatically various forms of segmented pads which are selectively produced 3,11%,994 Patented Dec. Z4, 1963 ice 2 respectively under control of the cams shown in FIGS. 9 through ll.

FIG. 15 is a cross section through a segmented pad fabricated according to the present invention.

The overall structure and operation of the basic apparatus is described in my copending application aforesaid to which reference is made for any details not necessary to a description of the present invention. Briefly, it is clear from FIGS. 1 and 5 herein that belt conveyor 20 carries in the direction of arrow 56 an envelope or sleeve 2l within which are spaced discrete batt sections 22 with subdividing gaps 23A therebetween. As in the copending application aforesaid, it is the function of the embosserknife unit herein disclosed to seal together the portions of the opposite plies 24, 25 of the envelope 21 which span across each gap 23. In the course of ensleeving the batt sections 22 within envelope 21, adhesive is coated upon the facing surfaces of the plies 24, 2S.

The e-nsleeved -batt sections are lfed by conveyor 2.0 over an anvil 26 and thence 4to a take-away conveyor 27 which is driven at the same speed as conveyor 2t?. Above the anvil 26 is disposed a supporting framework 32 for the embossing bars 30. These bars may simply consist of angle irons extending transversely of conveyor 2tl= and in vertical alignment with the anvil 26. The bars 3@ are spaced apart laterally and the space therebetween aligns vertically with a slot 31 formed in the anvil 26.

The structure of the frame 32 and connection of the bars 3@ thereto is best shown in FIGS. l, 5 and 6. The bars 30 have guide pins 33 fixed at their lower ends to the bars 319, but which are free to slide vertically through suitable openings formed in the web 34 in the T-frame 32. Normally the bars 30 are biased to their maximum spacing from the web 34 by compression springs 35, the ends of which are located by pins 36 0n flanges 37 clamped by bolts 3S to the T-frame 32 and by pins 4l projecting upwardly from the angle bars 30.

T-frarne 32 is also provided with a iiXed cut-olf knife 42 which is aligned with the space between the bars 30 and with the slot 31 in anvil 26.

As best shown in FIGS. 2 and 6, the anvil 26 and T-frame 32 are provided with a carriage 43 consisting of laterally spaced bearing blocks 44 at opposite sides of the conveyor 25B' and which slide along guide rods 45. Bearing blocks 44 have inwardly projecting shelves 39 to which the ends of the anvil 26 are secured by bolts 40.

` The bearing blocks i4 also have outwardly projecting shelf brackets a6 on which guide pins 50 are mounted and on which tubular sleeves Si on the T-frame 32 are vertically reciprocable.

Each shelf 46 also supports at its undersurface a pneumatic motor 52, the piston rods 53 of which are connected by couplings 54 to the T-frame 32. Motors 52 are adapted to draw the T-frarne 32, embossing bars 30 and knife '42 downwardly from their position shown in FIG. 5 to their position shown in FIG. 6.

In the course of such movement cushion pads 55 on the embossing bars 3i) will first press the two plies 24, 25 of envelope 21 together lto ladhesively bond together these plies across the gaps 23 between batt sections 22. Downward movement of the bars 30 will be arrested by the anvil 26, whereupon springs 35 will yield to permit continued downward movement of the T-frame 32 to force the knife 42 through sealed together portions of the envelope and thus sever the envelope, as shown in FIG. 6. After severing the wrapper, knife 42 will enter the slot 31 formed in the anvil 26. Accordingly, envelope 21 will be embossed and severed, as shown in FIG. 1, during each complete cycle of the embosser-knife unit.

During its embossing and severing cycle, the embosserknife unit is moved on its carriage 43 on a path parallel to the conveyor and at substantially the same speed. In the device of the copending `application aforesaid, a cam having a curved track was used to transmit longitudinal motion to the embosser-knife unit. This motion was transmitted to the embosser-knife unit `at -a point midway between the edges of the conveyor. For larger machines in which the width of the conveyor is materially increased over those heretofore used, midpoint drive to the embosser-knife unit has not proven to be entirely satisfactory. In the device of the present invention, the embosser-knife unit is driven at its side margins. This precludes any possibility of side sway, cramping or erratic movement, as both side margins of the unit are driven positively'.

As best shown in FIGS. 2 and 3, the carriage bearing blocks 44 have bracket arms 57 to which pitmans 58 are pivotally connected at corresponding ends on pins 61. The other corresponding ends of the pitmans 5S are connected on pins 62 to the crank arms 63, which are in turn mounted on transverse drive shaft 64. Each crank arm 63 can be adjusted radially with respect to the axis of drive shaft 62 by manipulating adjusting screws 65, thus to vary the throw of the pitmans 58.-

Shaft `64 is selectively driven from line shaft 69 by an electromagnetic clutch 66 which is driven by the dual chains 67 from the jack shaft 70 in geared connection to line shaft 69. There is also an electromagnetic brake 71 which selectively couples shaft 64 and chain 67. The respective windings of the clutch 66 and brake 71 are electrically interlocked so that energization of one winding will automatically deenergize the other winding.

As in the device of the copending application aforesaid, an electric counter 78 (FIG. 8) controls the initiation of the embosser-knife unit cycle by pulsing electric controller 37 and thus energizing clutch 66 and releasing brake 71. At the completion of the cycle, stop switch 72 is opened, as will hereinafter be described, to suitable pulse electric controller S7 to reapply brake 71 and release the clutch 66. The embosser-knife unit will then await re-initiation of the cycle by the counter 78.

An important feature of the device of the present invention is the mechanism and control means by which the knife 42 is selectively interlocked against severing the envelope 21 across the gaps between filler pads 22. The mechanism comprises slidable stop abutments 73, best shown in FIGS. 3 and 4, which are disposed at both sides of the conveyor 20. The abutments have pneumatic motors 74 by which they are selectively projected to their positions shown in dotted lines in FIG. 4 in which they intervene between the shelves 46 and the coupling blocks 54 by which the piston rods 53 of the pneumatic motors 52 are connected to the T-frame 32.

The abutment blocks 73 have upper surf-ace cushions 75 which function as shock absorbers. Blocks 73 are guided for reciprocating motion by the guide rails 76.

When the blocks 73 remain retracted in their position shown in FIG. 3, energization of the pneumatic motors 52 will result in complete cycling of the knife 42 to sever the embossed web of the envelope 21, as shown in FIGS. 1 and 6. However, if the motors 74 are energized to project the stop abutments 73 `to their position shown in dotted lines in FIG. 4, the knife 42 will be locked against severing the envelope because it will not be permitted -to descend far enough to engage the web.

This will not militate against completion of the cycle or jam the operation of the machine, because the pneumatic motors 52 inherently constitute lost motion connections to the T-frame 32. The air pressure on to-p of the pistons in the motors 52 will simply build up within permissible limits, even though the travel of pistons therein has been stopped.

The control of the cycle of operations oi the embosserknife unit will now be described. Particular reference will be made to the schematic diagram of FIG. 8 and A the physical positions of the various control switches shown in FIGS. 2, 3 and 7.

Note that there is a cam shaft 77 driven by chain 80 to turn at the same rate of rotation as drive shaft 64. Shaft 77 carries three cams 81, 82, 83, which respectively actuate switches 34, 72, 85.

Cam 81 and switch 34 control the electrically operated air valves 36 so that when the switch 34 is closed, valves 86 will be drawn to a position in which the motors 52 will be energized to draw the T-frame 32 downwardly. When switch 35 is engaged by cam 82, valves 86 will be drawn to their opposite position in which the motors 52 will be energized to raise the T-bar 32. The valves 86 are of the type that will remain in either position to which they are thrown, until reversed.

Switch 72 which is subject to actuation by the cam 83 is in circuit through the electric controller 87 with the electromagnetic brake 71 so that when switch 72 is closed, brake 71 will be applied and clutch 66 automatically released to stop shaft 64 from rotating.

With particular reference to the circuitry thus far described, the operation is as follows:

Assuming that the carriage is at its initial retracted position and electric counter 78 signals the controller 87 to start the cycle, clutch 66 will be engaged and brake 71 released to transmit power from the line shaft 69 through the chain 67, to the drive shaft 64 and thence through the crank and pitman connections aforesaid to move the carriage 43 in the direction of arrow 56.

Rotation of drive shaft 64 will be transmitted through chain Sil to drive cam shaft 77 in the direction of arrow 9i) in FIG. 2. After predetermined angular rotation of the cam shaft 77, during which the carriage will build up speed approximately that of the conveyor 29, cam 81 will engage switch S4 to energize the pneumatic motors 52 to draw the embosser-knife unit downwardly toward anvil 26 to perform the embossing and cut off operations hereinbefore described. After a period of further rotation of the cam shaft 77 during which the web is embossed and severed, cam S2 will engage switch 85 to reverse the position of the valves 36 and energize motors 52 to lift the embosser-knife unit upwardly and away from the anvil 26.

At the completion of of rotation of shaft 64, the crank and pitman combination will reverse the direction of movement of carriage 43 to bring the embosser-knife back to its initial position. When the return stroke of the carriage is nearly completed, cam 83 will engage stop switch 72 to release clutch 66 and apply brake 71. In the last few degrees of rotation of shaft 77, the momentum of the carriage will cause it to overrun the application of brake 71 and return to its initial position where it will await re-actuation of the clutch 66 upon signal from the electric counter 78.

The circuitry and operating components by which the knife lock 73 is operated will now be described. The purpose of the knife lock is to interlock the knife against actuation where it is desired that the sleeve 21 he embossed between pad segments 109 but not severed by the knife, thus leaving connecting links 108 of embossed sleeve portions intermediate pad segments, as is illustrated in FIGS. l2 through 15.

According to the present invention, segmented pads having two, three or four pad segments with intercon necting links therebetween can be produced at the option of the operator. One or another of switches 91, 92, 93 is optionally placed in the circuit shown in FIG. 8 by selective closure of the appropriate hand operated switches 94, 95, 96. If no switch 94, 95, 96 is closed, the knife will operate for each embossing cycle. However, if one or another of the switches 94, 95, 96 is closed, it will place its appropriate switch 91, 92, 93 in circuit with the electrically actuated air valves 97 for the pneumatic` motors 74.

Switches 91, 92, 93 are subject to actuation by the respective cams 9S, 99, 10i). These cams are mounted on a cam shaft 193 driven through a gear reducing train indicated generically by reference character 194 and which drives the cam shaft 193 in timed relation with cam shaft 77, but at 1/12 the speed thereof. Accordingly, each cam 93, 99, l'tl will turn through 1/12 of a revolution for every full revolution of the cam shaft 77.

Cam 93 has six equally spaced switch actuating abut ments or buttons 165 mounted on its periphery, so as to actuate its switch 91 on alternate complete rotations of the cam shaft 77. Cam 99 has eight switch actuating abutments 196 mounted on its periphery to actuate its switch 92 on two successive rotations of the cam shaft 77, to skip the next rotation, to make contact on the next two rotations, and so on. Cam 19t) has nine buttons 197 to make contact with switch 93 on three successive rotations of cam shaft 77, to skip the next rotation, to make conI tact on the next three rotations, and so on. Accordingly, depending upon which switch 94, 95, 95 is closed, the knife interlock blocks 73 will be actuated by motors '74 to interlock the knife from actuation in the respective patterns shown in FIGS. 12 through 14 where the knife is respectively interlocked against engagement with the sleeve between two succeeding pads (FIG. 12), between three succeeding pads (FIG. 13), or between four succeed ing pads (FlG. 14). At the conclusion of each pattern, as established by the number of spacing of buttons on the cams 98, 99, 199, the interlock will be released to permit the knife to sever the web.

ln this manner, a segmented pad product is produced which has unsevered flexible link portions 198 between cushion pad segments 199. Accordingly, in the packing of furniture and the like, the segmented pad can be readily bent around corners of the furniture in the vicinity of the flexible links 108.

I claim:

1. A device of the character described and which is adapted to emboss a sleeve of wrapping material across gaps between spaced pads ensleeved in said wrapping material and to sever said sleeve through embossed pon tions thereof, said device comprising embossing means to press said wrapping material together across said gaps, a knife to sever the embossed material, means :to sequentially engage said embossing means and knife with said material and means to selectively interlock the knife against such engagement to prevent severing said material across certain of said gaps, the means to sequentially engage the embossing means and knife with the material comprising a pneumatic motor having a lost motion connection with the knife, said interlock means comprising means to arrest movement of the knife toward the material and shorten the stroke of the motor, said lost motion connection relieving strain on the motor notwithstanding arrest-ment of the knife.

2. A device of the character described and which is adapted to emboss a sleeve of wrapping material across gaps between spaced pads ensleeved in said wrapping material and to sever said sleeve through embossed portions thereof, said device comprising embossing means to press said wrapping material together across said gaps, a knife to sever the embossed material, means to sequentially engage said embossing means and knife with said material land means to selectively interlock the knife against such engagement to prevent severing said material across certain of said gaps, in combination with a conveyor on which the sleeve is moved past the embossing means and knife, the means to sequentially engage the embossing means and knife with the material comprising means in timed coordination with the movement of said conveyor whereby the embossing means and knife are engaged with the material only across said gaps, said interlocking means comprising means to selectively interlock the knife against engagement with the sleeve in one or another of several patterns in each of which the knife engages the sleeve at certain of said gaps and does not engage the sleeve at other of said gaps whereby for each pattern a different series of pads interconnected by one or more embossed wrapping material links are produced on said device, said interlocking means further comprising a motor, an electrically actuated controller for the motor, an electric circuit for the controller, switch means for each said pattern, means coordinated with conveyor movement for selectively actuating said switch means, and means for placing in said circuit one or :another of said switch means in accordance with the desired pattern.

3. An apparatus for selectively fabricating one wrapped pad or a plurality of wrapped pads linked together by pad wrapping material, an embosser knife unit comprising an anvil, a frame spaced from the anvil for passage of pads therebetween, a knife fixed on the frame, an embossing bar yieldably mounted on the frame ahead of the knife and retractable on its mounting to permit the knife to coact with the anvil, means to advance the frame toward the anvil, a ledge Xed with respect to said anvil, said frame having a part which moves on a path toward the ledge when the frame advances toward the anvil, a stop abutment having guide means on which it is shiftable transversely to said path between one position clear of said path and another position in said path Where it is interposed between said part and said ledge to block advance of said frame short of coaction of the knife with the anvil, and a motor for moving said stop abutment along said guide means and control means for said motor to selectively interlock the knife against coaction with the anvil.

4. The apparatus of claim 3 in which said abutment is provided with a shock absorbing cushion.

References Cited in the le of this patent UNITED STATES PATENTS 1,510,261 Daniels Sept. 30; 1924 1,677,180 Green et al July 17, 1928 2,083,617 Salisberg June 15, 1937 2,379,937 Sloan July 10, 19415 2,578,799 Grey Dec. 18, 1951 2,661,835 Grishaber Dec. 8, 1953 2,806,100 Aalseth Aug. 20', 1957 2,808,691 Moore Oct. 8, 1957 2,874,826 Matthews et al Feb. 24, 1959 2,918,7 69 Anderson et al Dec. 29, 1959 2,951,325 Podlesak et al Sept. 6, 1960` 

2. A DEVICE OF THE CHARACTER DESCRIBED AND WHICH IS ADAPTED TO EMBOSS A SLEEVE OF WRAPPING MATERIAL ACROSS GAPS BETWEEN SPACED PADS ENSLEEVED IN SAID WRAPPING MATERIAL AND TO SEVER SAID SLEEVE THROUGH EMBOSSED PORTIONS THEREOF, SAID DEVICE COMPRISING EMBOSSING MEANS TO PRESS SAID WRAPPING MATERIAL TOGETHER ACROSS SAID GAPS, A KNIFE TO SEVER THE EMBOSSED MATERIAL, MEANS TO SEQUENTIALLY ENGAGE SAID EMBOSSING MEANS AND KNIFE WITH SAID MATERIAL AND MEANS TO SELECTIVELY INTERLOCK THE KNIFE AGAINST SUCH ENGAGEMENT TO PREVENT SEVERING SAID MATERIAL ACROSS CERTAIN OF SAID GAPS, IN COMBINATION WITH A CONVEYOR ON WHICH THE SLEEVE IS MOVED PAST THE EMBOSSING MEANS AND KNIFE, THE MEANS TO SEQUENTIALLY ENGAGE THE EMBOSSING MEANS AND KNIFE WITH THE MATERIAL COMPRISING MEANS IN TIMED COORDINATION WITH THE MOVEMENT OF SAID CONVEYOR WHEREBY THE EMBOSSING MEANS AND KNIFE ARE ENGAGED WITH THE MATERIAL ONLY ACROSS SAID GAPS, SAID INTERLOCKING MEANS COMPRISING MEANS TO SELECTIVELY INTERLOCK THE KNIFE AGAINST ENGAGEMENT WITH THE SLEEVE IN ONE OR ANOTHER OF SEVERAL PATTERNS IN EACH OF WHICH THE KNIFE ENGAGES THE SLEEVE AT CERTAIN OF SAID GAPS AND DOES NOT 